Vega VEGACAL 63 Capacitive rod probe for continuous level measurement Operating instructions

Operating Instructions

Capacitive rod electrode for continuous level measurement

VEGACAL 63

4 … 20 mA/HART - two-wire

Document ID: 30027

2

Contents

Contents

1 About this document

1.1 Function ........................................................................................................................... 4

1.2 Target group ..................................................................................................................... 4

1.3 Symbols used................................................................................................................... 4

2 For your safety

2.1 Authorised personnel ....................................................................................................... 5

2.2 Appropriate use ................................................................................................................ 5

2.3 Warning about incorrect use ............................................................................................. 5

2.4 General safety instructions ............................................................................................... 5

2.5 Safety label on the instrument .......................................................................................... 6

2.6 EU conformity ................................................................................................................... 6

2.7 Fulfillment of NAMUR recommendations ......................................................................... 6

2.8 Installation and operation in the USA and Canada ........................................................... 6

2.9 Safety instructions for Ex areas ........................................................................................ 6

2.10 Environmental instructions ............................................................................................... 6

3 Product description

3.1 Configuration .................................................................................................................... 8

3.2 Principle of operation........................................................................................................ 9

3.3 Adjustment ..................................................................................................................... 10

3.4 Packaging, transport and storage ................................................................................... 11

3.5 Accessories and replacement parts ............................................................................... 11

4 Mounting

4.1 General instructions ....................................................................................................... 13

4.2 Mounting instructions ..................................................................................................... 15

5 Connecting to power supply

5.1 Preparing the connection ............................................................................................... 17

5.2 Connection procedure .................................................................................................... 18

5.3 Wiring plan, single chamber housing.............................................................................. 19

5.4 Wiring plan, double chamber housing ............................................................................ 21

5.5 Wiring plan, Ex-d double chamber housing .................................................................... 23

5.6 Wiring plan - version IP 66/IP 68, 1 bar ........................................................................... 25

6 Set up with the display and adjustment module PLICSCOM

6.1 Short description ............................................................................................................ 26

6.2 Insert display and adjustment module ............................................................................ 26

6.3 Adjustment system ......................................................................................................... 27

6.4 Setup steps .................................................................................................................... 28

6.5 Menu schematic ............................................................................................................. 38

6.10 Saving the parameterisation data ................................................................................... 39

7 Set up with PACTware and other adjustment programs

7.1 Connect the PC .............................................................................................................. 40

7.2 Parameter adjustment with PACTware ............................................................................ 41

7.3 Parameter adjustment with AMS™ and PDM ................................................................. 42

7.4 Saving the parameterisation data ................................................................................... 43

8 Maintenance and fault rectification

8.1 Maintenance .................................................................................................................. 44

VEGACAL 63 • 4 … 20 mA/HART - two-wire

Contents

8.2 Rectify faults ................................................................................................................... 44

8.3 Exchanging the electronics module ................................................................................ 45

8.4 How to proceed if a repair is necessary .......................................................................... 46

9 Dismount

9.1 Dismounting steps.......................................................................................................... 47

9.2 Disposal ......................................................................................................................... 47

10 Supplement

10.1 Technical data ................................................................................................................ 48

10.2 Dimensions .................................................................................................................... 55

10.3 Industrial property rights ................................................................................................. 58

10.4 Trademark ...................................................................................................................... 58

Supplementary documentation

Information:

Supplementary documents appropriate to the ordered version come with the delivery. You can find them listed in chapter "Product descrip-

tion".

Instructions manuals for accessories and replacement parts

Tip:

To ensure reliable setup and operation of your VEGACAL 63, we offer accessories and replacement parts. The corresponding documentations are:

• 27720 - VEGADIS 61

30531 - Electronics module VEGACAL series 60

• 34296 - Protective cover

31088 - Flanges according to DIN-EN-ASME-JIS

Editing status: 2017-04-06

VEGACAL 63 • 4 … 20 mA/HART - two-wire 3

4

1 About this document

1 About this document

1.1 Function

This operating instructions manual provides all the information you need for mounting, connection and setup of the instrument. Furthermore there are important instructions for maintenance, fault rectification, the exchange of parts and the safety of the user. Please read this information before putting the instrument into operation and keep this manual accessible in the immediate vicinity of the device.

1.2 Target group

This operating instructions manual is directed to trained specialist personnel. The contents of this manual should be made available to these personnel and put into practice by them.

1.3 Symbols used

Information, tip, note

This symbol indicates helpful additional information.

Caution: If this warning is ignored, faults or malfunctions can result.

Warning: If this warning is ignored, injury to persons and/or serious damage to the instrument can result.

Danger: If this warning is ignored, serious injury to persons and/or destruction of the instrument can result.

Ex applications

This symbol indicates special instructions for Ex applications.

SIL applications

This symbol indicates instructions for functional safety which must be taken into account particularly for safety-relevant applications.

•

List

The dot set in front indicates a list with no implied sequence.

→

Action

This arrow indicates a single action.

1 Sequence of actions

Numbers set in front indicate successive steps in a procedure.

Battery disposal

This symbol indicates special information about the disposal of batteries and accumulators.


2 For your safety

2 For your safety

2.1 Authorised personnel

All operations described in this operating instructions manual must be carried out only by trained specialist personnel authorised by the plant operator.

During work on and with the device the required personal protective equipment must always be worn.

2.2 Appropriate use

VEGACAL 63 is a sensor for continuous level measurement.

You can find detailed information about the area of application in chapter "Product description".

Operational reliability is ensured only if the instrument is properly used according to the specifications in the operating instructions manual as well as possible supplementary instructions.

For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbitrary conversions or modifications are explicitly forbidden.

2.3 Warning about incorrect use

Inappropriate or incorrect use of the instrument can give rise to application-specific hazards, e.g. vessel overfill or damage to system components through incorrect mounting or adjustment. Thus damage to property, to persons or environmental contamination can be caused. Also the protective characteristics of the instrument can be influenced.

2.4 General safety instructions

This is a state-of-the-art instrument complying with all prevailing regulations and directives. The instrument must only be operated in a technically flawless and reliable condition. The operator is responsible for the trouble-free operation of the instrument. When measuring aggressive or corrosive media where a malfunction of the instrument can cause a danger, the operator has to convince himself on the correct function of the instrument by taking suitable measures.

During the entire duration of use, the user is obliged to determine the compliance of the necessary occupational safety measures with the current valid rules and regulations and also take note of new regulations.

The safety instructions in this operating instructions manual, the national installation standards as well as the valid safety regulations and accident prevention rules must be observed by the user.

For safety and warranty reasons, any invasive work on the device beyond that described in the operating instructions manual may be carried out only by personnel authorised by the manufacturer. Arbitrary conversions or modifications are explicitly forbidden. For safety


6

2 For your safety reasons, only the accessory specified by the manufacturer must be used.

To avoid any danger, the safety approval markings and safety tips on the device must also be observed and their meaning looked up in this operating instructions manual.

2.5 Safety label on the instrument

The safety approval markings and safety tips on the device must be observed.

2.6 EU conformity

The device fulfils the legal requirements of the applicable EU directives. By affixing the CE marking, we confirm successful testing of the product.

You can find the EU conformity declaration on our website under www.vega.com/downloads.

2.7 Fulfillment of NAMUR recommendations

NAMUR is the automation technology user association in the process industry in Germany. The published NAMUR recommendations are accepted as the standard in field instrumentation.

The device fulfils the requirements of the following NAMUR recommendations:

• NE 21 – Electromagnetic compatibility of equipment

NE 43 – Signal level for fault information from measuring transduc-

• ers

NE 53 – Compatibility of field devices and display/adjustment components

For further information see www.namur.de.

2.8 Installation and operation in the USA and

Canada

This information is only valid for USA and Canada. Hence the following text is only available in the English language.

Installations in the US shall comply with the relevant requirements of the National Electrical Code (ANSI/NFPA 70).

Installations in Canada shall comply with the relevant requirements of the Canadian Electrical Code

2.9 Safety instructions for Ex areas

Please note the Ex-specific safety information for installation and operation in Ex areas. These safety instructions are part of the operating instructions manual and come with the Ex-approved instruments.

2.10 Environmental instructions

Protection of the environment is one of our most important duties.

That is why we have introduced an environment management system


2 For your safety with the goal of continuously improving company environmental protection. The environment management system is certified according to DIN EN ISO 14001.

Please help us fulfil this obligation by observing the environmental instructions in this manual:

• Chapter "Packaging, transport and storage"

Chapter "Disposal"


8

3 Product description

Scope of delivery

Constituent parts

3 Product description

3.1 Configuration

The scope of delivery encompasses:

• Level sensor VEGACAL 63

Documentation

– This operating instructions manual

– Safety Manual "Functional safety (SIL)" (optional)

– Supplementary instructions manual "Heating for display and

adjustment module" (optional)

– Supplementary instructions manual "Plug connector for con-

tinuously measuring sensors" (optional)

– Ex-specific "Safety instructions" (with Ex versions)

– If necessary, further certificates

The VEGACAL 63 consists of the components:

• Process fitting with probe

Housing with electronics

Housing lid

1

2

3

Type label

Fig. 1: VEGACAL 63, rod version with plastic housing

1 Housing lid

2 Housing with electronics

3 Process fitting

The type label contains the most important data for identification and use of the instrument:


Application area

Functional principle


1

2

3

15

14

13

4 12

5

6

7

8

11

10

9

Fig. 2: Layout of the type label (example)

1 Instrument type

2 Product code

3 Approvals

4 Process and ambient temperature, process pressure

5 Power supply and signal output, electronics

6 Protection rating

7 Probe length

8 Order number

9 Serial number of the instrument

10 Material, wetted parts

11 Symbol of the device protection class

12 Reminder to observe the instrument documentation

13 ID numbers, instrument documentation

14 Notified authority for CE marking

15 Approval directives

With the serial number, you can access the delivery data of the instrument via "www.vega.com", "VEGA Tools" and "Instrument search".

You can find the serial number on the inside of the instrument as well as on the type label on the outside.

3.2 Principle of operation

The VEGACAL 63 sensor can be used universally for level measurement in conductive and non-conductive liquids.

The rod probe is fully insulated and the proven mechanical construction offers high functional safety.

Probe, measured product and vessel wall form an electrical capacitor.

The capacitance is influenced by three main factors.



1

Voltage supply

10

2

3

Fig. 3: Functional principle - Plate capacitor

1 Distance between the electrode surfaces

2 Size of the electrode surfaces

3 Type of dielectric between the electrodes

The probe and the vessel wall are the capacitor plates. The measured product and the insulation are the dielectric. Due to the higher dielectric constant of the insulation and the conductive product compared to air, the capacitance increases as the probe is gradually covered.

The capacitance as well as the resistance change are converted by the electronics module into a level-proportional signal.

4 … 20 mA/HART two-wire electronics for voltage supply and measured value transmission on the same cable.

The supply voltage range can differ depending on the instrument version.

The data for power supply are specified in chapter "Technical data".

The backlight of the display and adjustment module is powered by the sensor. The prerequisite for this is a supply voltage at a certain level. The exact voltage specifications are stated in chapter "Technical

data".

The optional heating requires its own power supply. You can find further details in the supplementary instructions manual "Heating for

display and adjustment module".

This function is generally not available for approved instruments.

3.3 Adjustment

The instrument can be adjusted with the following adjustment media:

• With the display and adjustment module with the suitable VEGA DTM in conjunction with an adjustment software according to the FDT/DTM standard, e.g. PACTware and

PC

• With manufacturer-specific adjustment programs AMS™ or PDM

With a HART handheld


Packaging

Transport

Transport inspection

Storage

Storage and transport temperature

Lifting and carrying

PLICSCOM


3.4 Packaging, transport and storage

Your instrument was protected by packaging during transport. Its capacity to handle normal loads during transport is assured by a test based on ISO 4180.

The packaging of standard instruments consists of environmentfriendly, recyclable cardboard. For special versions, PE foam or PE foil is also used. Dispose of the packaging material via specialised recycling companies.

Transport must be carried out in due consideration of the notes on the transport packaging. Nonobservance of these instructions can cause damage to the device.

The delivery must be checked for completeness and possible transit damage immediately at receipt. Ascertained transit damage or concealed defects must be appropriately dealt with.

Up to the time of installation, the packages must be left closed and stored according to the orientation and storage markings on the outside.

Unless otherwise indicated, the packages must be stored only under the following conditions:

• Not in the open

Dry and dust free

• Not exposed to corrosive media

Protected against solar radiation

• Avoiding mechanical shock and vibration

• Storage and transport temperature see chapter "Supplement -

Technical data - Ambient conditions"

• Relative humidity 20 … 85 %

With an instrument weight of more than 18 kg (39.68 lbs) suitable and approved equipment must be used for lifting and carrying.

3.5 Accessories and replacement parts

The display and adjustment module PLICSCOM is used for measured value indication, adjustment and diagnosis. It can be inserted into the sensor and removed at any time.

The integrated Bluetooth module (optional) enables wireless adjustment via standard adjustment devices: 1)

• Smartphone/tablet (iOS or Android operating system)

PC/notebook with Bluetooth USB adapter (Windows operating system)

You can find further information in the operating instructions "Display

and adjustment module PLICSCOM" (Document-ID 27835).

1) Bluetooth function with VEGADIS 82 can only be used at a later date.



VEGACONNECT

VEGADIS 82

Protective cover

Flanges

Screening tube adapter

The interface adapter VEGACONNECT enables the connection of communication-capable instruments to the USB interface of a PC. For parameter adjustment of these instruments, the adjustment software

PACTware with VEGA-DTM is required.

You can find further information in the operating instructions "Interface

adapter VEGACONNECT" (Document-ID 32628).

VEGADIS 82 is suitable for measured value indication and adjustment of sensors with HART protocol. It is looped into the 4 … 20 mA/HART signal cable.

You can find further information in the operating instructions

"VEGADIS 82 4 … 20 mA/HART" (Document-ID 45300).

The protective cover protects the sensor housing against soiling and intense heat from solar radiation.

You will find additional information in the supplementary instructions manual "Protective cover" (Document-ID 34296).

Screwed flanges are available in different versions according to the following standards: DIN 2501, EN 1092-1, BS 10, ASME B 16.5,

JIS B 2210-1984, GOST 12821-80.

You can find additional information in the supplementary instructions manual "Flanges according to DIN-EN-ASME-JIS".

There are different reasons for the use of a screening tube adapter.

Condensation

In case of strong condensation, the draining of condensed water can change the measurement accuracy. The suitable version is the

Screening against condensation. The condensation can drain off outside on the screening tube adapter.

Typical applications of the screening tube adapters are e.g. for condensation or sockets. Apart from the standard version, there is a second version for vacuum with a sepcial seal. When the screening tube adapter is submerged in liquid, we recommend the use of a vacuum-tight version.

Mounting socket

In case of long sockets, the screening tube can increase the sensitivity of the probe by compensating the influences of the socket. The suitable version is Capacitive screening, vacuum-tight.

When the probe is mounted laterally, buildup can accumulate in the socket. A screening tube makes the covered part of the probe inactive and hence insensitive to influence from buildup and socket. Hence, the screening tube adapter excludes changing influences caused by the medium and ensures stable measurement conditions. The suitable version is Capacitive screening, vacuum-tight.

12 VEGACAL 63 • 4 … 20 mA/HART - two-wire

4 Mounting

4 Mounting

Suitability for the process conditions

4.1 General instructions

Make sure that all parts of the instrument coming in direct contact with the process, especially the sensor element, process seal and process fitting, are suitable for the existing process conditions, such as process pressure, process temperature as well as the chemical properties of the medium.

You can find the specifications in chapter "Technical data" and on the nameplate.

Suitability for the ambient conditions

The instrument is suitable for standard and extended ambient conditions acc. to DIN/EN/IEC/ANSI/ISA/UL/CSA 61010-1.

Installation position

Welding work

Handling

Select an installation position you can easily reach for mounting and connecting as well as later retrofitting of a display and adjustment module. The housing can be rotated by 330° without the use of any tools. You can also install the display and adjustment module in four different positions (each displaced by 90°).

Before beginning the welding work, remove the electronics module from the sensor. By doing this, you avoid damage to the electronics through inductive coupling.

Ground the probe before welding directly on the rod or cable.

With threaded versions, the housing must not be used to screw in the instrument! Applying tightening forces on the housing can damage its internal parts.

Use the hexagon for screwing in.

Moisture Use the recommended cables (see chapter "Connecting to power

supply") and tighten the cable gland.

You can give your instrument additional protection against moisture penetration by leading the connection cable downward in front of the cable entry. Rain and condensation water can thus drain off. This applies mainly to outdoor mounting as well as installation in areas where high humidity is expected (e.g. through cleaning processes) or on cooled or heated vessels.

To maintain the housing protection, make sure that the housing lid is closed during operation and locked, if necessary.

Make sure that the degree of contamination specified in chapter

"Technical data" meets the existing ambient conditions.


4 Mounting

Pressure/Vacuum

Vessel material

Vessel forms

Cable entries - NPT thread

Cable glands

14

Fig. 4: Measures against moisture ingress

The process fitting must be sealed if there is gauge or low pressure in the vessel. Before use, check if the seal material is resistant against the measured product and the process temperature.

The max. permissible pressure is specified in chapter "Technical

data" or on the type label of the sensor.

Insulating measures, such as e.g. covering the thread with teflon tape, can interrupt the necessary electrical connection with metal vessels.

For this reason, ground the probe on the vessel or use a conductive seal material.

Metal vessel

Make sure that the mechanical connection of the probe to the vessel is electrically conductive to ensure sufficient grounding.

Use conductive seals, such as those made of copper or lead, etc.

Insulating measures, such as covering the thread with Teflon tape, can interrupt the necessary electrical connection with metal vessels.

For this reason, ground the probe on the vessel or use a conductive seal material.

Non-conductive vessels

In non-conductive vessels, e.g. plastic tanks, the second pole of the capacitor must be provided separately, e.g. in the form of a concentric tube.

If possible, the capacitive probe should be mounted vertically or parallel to the counter electrode. This applies particularly to applications in non-conductive products.

In cylindrical tanks, spherical tanks or other asymmetrical tank forms, nonlinear level values are generated due to the varying distance to the vessel wall.

Use a concentric tube in non-conductive products or linearize the meas. signal.

Metric threads

In the case of instrument housings with metric thread, the cable glands are screwed in at the factory. They are sealed with plastic plugs as transport protection.

You have to remove these plugs before electrical connection.


Installation position

4 Mounting

NPT thread

In the case of instrument housings with self-sealing NPT threads, it is not possible to have the cable entries screwed in at the factory. The free openings for the cable glands are therefore covered with red dust protection caps as transport protection.

Prior to setup you have to replace these protective caps with approved cable glands or close the openings with suitable blind plugs.

4.2 Mounting instructions

During operation, the probe must not touch any installations or the vessel wall. The measured value can also change if the distance to the vessel wall changes considerably. If necessary, secure the end of the probe (insulated).

1 1

2 2

Inflowing medium

Fig. 5: Fasten the probe

1 Measuring probe

2 Plastic socket

In vessels with conical bottom it can be advantageous to mount the sensor in the centre of the vessel, as measurement is then possible down to the bottom.

If the instrument is mounted in the filling stream, unwanted false measurement signals can be generated. For this reason, mount the instrument at a position in the vessel where no disturbances, e.g. from filling openings, agitators, etc., can occur.

This applies particularly to instrument versions with a longer probe.


4 Mounting

Fig. 6: Inflowing medium

Torque with PTFE plated flanges

To compensate the material-specific preload loss due to sealing materials, you have to additionally use disc springs for fastening flange screws on PTFE coated flanges. Tighten the screws moderately with the torque stated in the technical data. Depending on the process and ambient conditions, this value can vary. In individual cases you should occasionally check the tightness on site.


Safety instructions

Voltage supply

Connection cable

5 Connecting to power supply

5 Connecting to power supply

5.1 Preparing the connection

Always keep in mind the following safety instructions:

Warning:

Connect only in the complete absence of line voltage.

• The electrical connection must only be carried out by trained personnel authorised by the plant operator.

• If overvoltage surges are expected, overvoltage arresters should be installed.

Power supply and current signal are carried on the same two-wire cable. The operating voltage can differ depending on the instrument version.

The data for power supply are specified in chapter "Technical data".

Provide a reliable separation between the supply circuit and the mains circuits according to DIN EN 61140 VDE 0140-1.

Power the instrument via an energy-limited circuit acc. to DIN/EN/IEC/

ANSI/ISA/UL/CSA 61010-1, e.g. via Class 2 power supply unit acc. to

UL 1310 or an SELV power supply unit with suitable external current limitation.

2)

Keep in mind the following additional factors that influence the operating voltage:

• Lower output voltage of the power supply unit under nominal load

(e.g. with a sensor current of 20.5 mA or 22 mA in case of fault)

• Influence of additional instruments in the circuit (see load values in chapter "Technical data")

The instrument is connected with standard two-wire cable without screen. If electromagnetic interference is expected which is above the test values of EN 61326-1 for industrial areas, screened cable should be used.

Make sure that the cable used has the required temperature resistance and fire safety for max. occurring ambient temperature

Use cable with round cross section for instruments with housing and cable gland. To ensure the seal effect of the cable gland (IP protection rating), find out which cable outer diameter the cable gland is suitable for.

Use a cable gland fitting the cable diameter.

We generally recommend the use of screened cable for HART multidrop mode.

2) Class 2 power supply unit: limited voltage and power level, special insulation against circuits with higher voltage. SELV (Safety Extra Low Voltage) power supply unit: limited voltage level, special insulation against circuits with higher voltage



Cable glands

Cable screening and grounding

Metric threads

In the case of instrument housings with metric thread, the cable glands are screwed in at the factory. They are sealed with plastic plugs as transport protection.

You have to remove these plugs before electrical connection.

NPT thread

In the case of instrument housings with self-sealing NPT threads, it is not possible to have the cable entries screwed in at the factory. The free openings for the cable glands are therefore covered with red dust protection caps as transport protection.

Prior to setup you have to replace these protective caps with approved cable glands or close the openings with suitable blind plugs.

On plastic housings, the NPT cable gland or the Conduit steel tube must be screwed into the threaded insert without grease.

If screened cable is required, we recommend connecting the cable screen on both ends to ground potential. In the sensor, the screen must be connected directly to the internal ground terminal. The ground terminal on the outside of the housing must be connected to the ground potential (low impedance).

In Ex systems, the grounding is carried out according to the installation regulations.

In electroplating plants as well as plants that apply cathodic corrosion protection, it must be taken into account that significant potential differences exist. This can lead to unacceptably high currents in the cable screen if it is grounded at both ends.

Information:

The metallic parts of the instrument (process fitting, housing, etc.) are conductively connected to the ground terminal.

Take note of the corresponding installation regulations for Ex applications. In particular, make sure that no potential equalisation currents flow over the cable screen. In case of grounding on both sides this can be achieved by the use of a capacitor or a separate potential equalisation.

5.2 Connection procedure

Proceed as follows:

1. Unscrew the housing lid

2. If a display and adjustment module is installed, remove it by turning it to the left.

3. Loosen compression nut of the cable gland and remove blind plug

4. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.

1 cm (0.4 in) of insulation from the ends of the individual wires

5. Insert the cable into the sensor through the cable entry



6. Lift the opening levers of the terminals with a screwdriver (see following illustration)

7. Insert the wire ends into the open terminals according to the wiring plan

Fig. 7: Connection steps 6 and 7

8. Press down the opening levers of the terminals, you will hear the terminal spring closing

9. Check the hold of the wires in the terminals by lightly pulling on them

10. Connect the screen to the internal ground terminal, connect the external ground terminal to potential equalisation

11. Tighten the compression nut of the cable entry gland. The seal ring must completely encircle the cable

12. Screw the housing lid back on

The electrical connection is finished.

5.3 Wiring plan, single chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-ia version.



Housing overview

5

1

5

2

5

3

Electronics and terminal compartment

5

4

Fig. 8: Material versions, single chamber housing

1 Plastic

2 Aluminium

3 Stainless steel (precision casting)

4 Stainless steel (electro-polished)

5 Filter element for air pressure compensation of all material versions. Blind plug with version IP 66/IP 68, 1 bar for Aluminium and stainless steel

Display

I²C

1

4 1 2 5 6 7 8

2

3

Fig. 9: Electronics and terminal compartment - single chamber housing

1 Plug connector for VEGACONNECT (I²C interface)

2 Spring-loaded terminals for connection of the external indication VEGADIS

61

3 Ground terminal for connection of the cable screen

4 Spring-loaded terminals for voltage supply



Wiring plan


Display

I2C

1 2 5 6 7 8

1

Fig. 10: Wiring plan - single chamber housing

1 Voltage supply, signal output

5.4 Wiring plan, double chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-ia version.

1 2 3

4

5

Fig. 11: Double chamber housing

1 Housing cover - connection compartment

2 Blind plug or plug M12 x 1 for VEGADIS 61 (optional)

3 Housing cover - electronics compartment

4 Filter element for air pressure compensation

5 Cable gland



Electronics compartment

Display

I²C

1 2 5 6 7 8

1

Terminal compartment

3

Fig. 12: Electronics compartment - double chamber housing


2 Internal connection cable to the connection compartment

3 Terminals for VEGADIS 81

2

2

1

1 2 I2C

Fig. 13: Terminal compartment - double chamber housing

1 Spring-loaded terminals for voltage supply



3



Wiring plan


I2C

1 2

1

Fig. 14: Wiring plan - double chamber housing


5.5 Wiring plan, Ex-d double chamber housing

1 2 3

4

5

Fig. 15: Double chamber housing

1 Housing cover - connection compartment

2 Blind plug or plug M12 x 1 for VEGADIS 61 (optional)

3 Housing cover - electronics compartment

4 Filter element for air pressure compensation

5 Cable gland



Electronics compartment

Display

I²C

1 2 5 6 7 8

1

Terminal compartment

3

Fig. 16: Electronics compartment - double chamber housing


2 Internal connection cable to the connection compartment

3 Terminals for VEGADIS 81

2

1

1 2

Fig. 17: Connection compartment, Ex-d-ia double chamber housing

1 Spring-loaded terminals for power supply and cable screen


2



Wiring plan

Wire assignment, connection cable

1 2

1

Fig. 18: Wiring plan, Ex-d-ia double chamber housing


5.6 Wiring plan - version IP 66/IP 68, 1 bar

1

2

Fig. 19: Wire assignment, connection cable

1 Brown (+) and blue (-) to power supply or to the processing system

2 Shielding


6 Set up with the display and adjustment module PLICSCOM

Function/Configuration

Mount/dismount display and adjustment module

6 Set up with the display and adjustment module PLICSCOM

6.1 Short description

The display and adjustment module is used for measured value display, adjustment and diagnosis. It can be mounted in the following housing versions and instruments:

• All sensors of the plics ® instrument family, in the single as well as in the double chamber housing (optionally in the electronics or connection compartment)

• External display and adjustment unit VEGADIS 61

6.2 Insert display and adjustment module

The display and adjustment module can be inserted into the sensor and removed again at any time. It is not necessary to interrupt the power supply.

Proceed as follows:

1. Unscrew the housing lid

2. Place the display and adjustment module in the desired position on the electronics (you can choose any one of four different positions - each displaced by 90°)

3. Press the display and adjustment module onto the electronics and turn it to the right until it snaps in

4. Screw housing lid with inspection window tightly back on

Disassembly is carried out in reverse order.

The display and adjustment module is powered by the sensor, an additional connection is not necessary.



Fig. 20: Insert display and adjustment module

Note:

If you intend to retrofit the instrument with a display and adjustment module for continuous measured value indication, a higher lid with an inspection glass is required.

6.3 Adjustment system

1

2

Key functions

Fig. 21: Display and adjustment elements

1 LC display

2 Indication of the menu item number

3 Adjustment keys

• [OK] key:



– Move to the menu overview

– Confirm selected menu

– Edit parameter

– Save value

• [->] key to select:

– Menu change

– Select list entry

– Select editing position

• [+] key:

– Change value of the parameter

• [ESC] key:

– Interrupt input

– Jump to next higher menu

Adjustment system

Time functions

Switch-on phase

Address setting HART multidrop

The instrument is operated via the four keys of the display and adjustment module. The individual menu items are shown on the LC display.

You can find the functions of the individual keys in the previous illustration.

When the [+] and [->] keys are pressed quickly, the edited value, or the cursor, changes one value or position at a time. If the key is pressed longer than 1 s, the value or position changes continuously.

When the [OK] and [ESC] keys are pressed simultaneously for more than 5 s, the display returns to the main menu. The menu language is then switched over to "English".

Approx. 60 minutes after the last pressing of a key, an automatic reset to measured value indication is triggered. Any values not confirmed with [OK] will not be saved.

6.4 Setup steps

After connecting VEGACAL 63 to power supply or after a voltage recurrence, the instrument carries out a self-check for approx. 30 seconds:

• Internal check of the electronics

Indication of the instrument type, the firmware as well as the sen-

• sor TAGs (sensor designation)

Output signal jumps briefly (approx. 10 seconds) to the set fault current

Then the corresponding current is outputted to the cable (the value corresponds to the actual level as well as the settings already carried out, e.g. factory setting).

In HART-Multidrop mode (several sensors on one input) the address must be set before continuing with the parameter adjustment. You will find a detailed description in the operating instructions manual

"Display and adjustment module" or in the online help of PACTware or DTM.



HART mode

Standard

Address 0

Parameter adjustment VEGACAL 63 measures the capacitance of the respective product. To display the actual level of the product, an allocation of the measured capacitance to the percentage height must be carried out. For this adjustment, the capacitance is entered with emptied and filled vessel.

If the vessel cannot be emptied or filled completely, you can carry out the adjustment also with two known levels - for example with 10 % and 90 %. The difference between the empty and full adjustment values should be as large as possible.

The actual level can then be calculated on the basis of these settings.

VEGACAL 63 must be installed. A change of level is necessary for this adjustment.

In the main menu item "Basic adjustment", the individual submenu items should be selected one after the other and provided with the correct parameter values.

Tip:

If the display and adjustment module remains on the probe as a display, we recommend saving the sensor data in the display and adjustment module.

Use the function "Copy sensor data".

Start your parameter adjustment with the following menu items of the basic adjustment:

Carry out min. adjustment To be on the safe side, note the adjustment values for full and empty.

If an adjustment procedure fails, it is not necessary to again carry out a level change.

These values can be helpful if the electronics has to be exchanged.

% Value

Empty adjustment

Full adjustment

Tab. 1: Adjustment protocol

Tip:

For min. adjustment the vessel should be as empty as possible, and for max. adjustment, as full as possible. If the vessel is already full, start with max. adjustment.

Note:

If possible, the vessel should be as empty as possible for min. adjustment.

Proceed as follows:

1. Move from the measured value display to the main menu by pushing [OK].



Carry out max. adjustment

▶ Basic adjustment

Display

Diagnostics

Service

Info

2. Select the menu item "Basic adjustment" with [->] and confirm with [OK]. Now the menu item "Min. adjustment" is displayed.

Min. adjustment

0.00 %

=

0.0 pF

54.5 pF

3. Prepare the adjustment value for editing with [OK]. Move to the selection window with [OK].

Min. adjustment

Accept current measured value?

Accept?

Edit?

4. Accept the current measured value or move to the editing window with "Edit". To edit, set the cursor to the requested position with

[->]. Set the requested % value with [+] and save with [OK]. The cursor jumps to the capacitance value.

5. Enter the current capacitance value in pF (displayed below) for the empty vessel corresponding to the percentage value.

6. Save the settings with [OK] and move to "Max. adjustment" with

[->].

Fill the vessel to the highest possible level.

Note:

For max. adjustment, the vessel should be as full as possible. This will make the calibration more accurate.

Proceed as follows:

Max. adjustment

100.00 %

=

1000 pF

327.4 pF

1. Prepare the adjustment value for editing with [OK]. Move to the selection window with [OK].

Min. adjustment

Accept current measured value?

Accept?

Edit?

2. Accept the current measured value or move to the editing window with "Edit". To edit, set the cursor to the requested position with

[->]. Set the requested % value with [+] and save with [OK]. The cursor jumps to the capacitance value.



3. Enter the current capacitance value in pF (displayed below) for the full vessel corresponding to the percentage value.

4. Save the settings with [OK].

Basic adjustment - Damping

To suppress fluctuations in the measured value display, e. g. caused by an agitated product surface, a damping can be set. This time can be between 0 and 999 seconds. Keep in mind that the reaction time of the entire measurement will then be longer and the sensor will react to measured value changes with a delay. In general, a period of a few seconds is sufficient to smooth the measured value display.

Damping

0 s

Basic adjustment - Linearization curve

Enter the requested parameters via the appropriate keys, save your settings and jump to the next menu item with the [->] key.

A linearisation is necessary for all vessels in which the vessel volume does not increase linearly with the level - e.g. in a horizontal cylindrical or spherical tank - and the indication or output of the volume is required. Corresponding linearisation curves are preprogrammed for these vessels. They represent the correlation between the level percentage and vessel volume. By activating the appropriate curve, the volume percentage of the vessel is displayed correctly. If the volume should not be displayed in percent but e.g. in l or kg, a scaling can be also set in the menu item "Display".

Linearisation curve

Linear

Basic adjustment - Sensor TAG

Enter the requested parameters via the appropriate keys, save your settings and jump to the next menu item with the [->] key.

Caution:

Note the following if the VEGACAL 63 with corresponding approval is used as part of an overfill protection system according to WHG (Water

Resources Act):

If a linearisation curve is selected, the measuring signal is no longer necessarily linear to the filling height. This must be considered by the user especially when setting the switching point on the limit signal transmitter.

In this menu item you can enter an unambiguous designation for the sensor, e.g. the measurement loop name or the tank or product designation. In digital systems and in the documentation of larger plants, a singular designation should be entered for exact identification of individual measuring points.



Sensor-TAG

Sensor

Display - Indicated value

With this menu item, the Basic adjustment is finished and you can now jump to the main menu with the [ESC] key.

In the menu item "Display" you can define how the measured value should be presented on the display.

The following indication values are available:

• Height

Distance

Current

• Scaled

Percent

• Lin. percent

The selection "scaled" opens the menu items "Display unit" and

"Scaling". In "Display unit" there are the following options:

• Height

Ground

• Flow

Volume

• Without unit

Depending on selection, the different units are in turn available.

In the menu item "Scaling", the requested numerical value with decimal point is entered for 0 % and 100 % of the measured value.

There is the following relationship between the indication value in the menu "Display" and the adjustment unit in the menu "Device settings":

• Indication value "Distance": Presentation of the measured value in the selected adjustment unit, e.g. m(d).

Displayed value

Scaled

▼

Display - Backlight

32

Display unit

Volume

▼ l

▼

Scaling

0 % = 0.0 l

100 % = 100.0 l

A background lighting integrated by default can be adjusted via the adjustment menu. The function depends on the height of the supply voltage. See "Technical data/Voltage supply".


Backlight


Diagnosis - Peak value

In the default setting, the lightning is switched off.

The respective min. and max. measured values are saved in the sensor. The values are displayed in the menu item "Peak values".

• Min. and max. distance in m(d)

Min. and max. temperature

Peak value indicator

Diagnostics - Device status

The instrument status is displayed in this menu item. If no failure is detected by the sensor, "OK" will be displayed. If a failure is detected, there will be a sensor-specific flashing fault signal, for example

"E013". The failure is also displayed in clear text, for example "No

measured value available".

Information:

The fault message as well as the clear text indication are also carried out in the measured value display.

Meas. certainty

Sensor status

Trend recording Up to 3000 measured values are recorded (depending on the sensor) when starting a "Trend curve". Then the values can be displayed on a time axis. The oldest measured values are always deleted.

The measured values displayed are in the unit pF.

Trend recording

Presentation of the trend curve

Service - Current output

Information:

The trend recording is not activated when being shipped. It must be started by the user via the menu item "Start trend curve".

In the menu item "Current output" you determine the behaviour of the current output during operation and in case of failure. The following options are available:



Current output

Characteristics

Failure mode 3)

Min. current 4)

Max. current 5)

4 … 20 mA

20 … 4 mA

Hold value

20.5 mA

22 mA

< 3.6 mA

3.8 mA

4 mA

20 mA

20.5 mA

The values in bold font represent the data of the factory setting.

In HART multidrop mode, the current is constantly 4 mA. This value does not change even in case of failure.

Current output

Characteristic: 4-20 mA

▼

Failure mode: 22 mA

▼

Min. current 3.8 mA

▼

Service - Simulation In this menu item you simulate a user-defined level or pressure value via the current output. This allows you to test the signal path, e.g. through connected indicating instruments or the input card of the control system.

The following simulation variables are available:

• Percent

Current

Pressure (with pressure transmitters)

• Distance (with radar and guided microwave)

With Profibus PA sensors, the selection of the simulated value is made via the "Channel" in the menu "Basic adjustments".

How to start the simulation:

34

2. Select the requested simulation variable with [->] and confirm with [OK].

3. Set the requested numerical value with [+] and [->].

The simulation is now running, with 4 … 20 mA/HART a current is outputted and with Profibus PA or Foundation Fieldbus a digital value.

How to interrupt the simulation:

→ Push [ESC]

3)

4)

5)

Value of the current output in case of failure, e.g. if no valid measured value is delivered.

This value is not underrun during operation.

This value is not exceeded during operation.


Reset

Service - Language


Information:

The simulation is automatically terminated 10 minutes after the last pressing of a key.

Simulation

Start simulation?

Basic adjustment

If the function "Reset" is carried out, the sensor resets all settings to default.

The following values will be reset:

Function

Max. adjustment

Min. adjustment

Damping ti

Linearisation

Sensor-TAG

Display

Current output - characteristics

Current output - max. current

Current output - min. current

Current output - failure

Reset value

3000 pF

0 pF

0 s

Linear

Sensor

%

4 … 20 mA

20.5 mA

3.8 mA

< 3.6 mA

Special parameters

All special parameters are reset to delivery status.

Peak value indicator

The min. and max. values are reset to the actual value.

The sensor is already set to the ordered national language. In this menu item you can change the language. The following languages are available, e.g. in software version 3.50:

• Deutsch

English

• Français

Espanõl

• Pycckuu

Italiano

• Netherlands

Japanese

• Chinese

Language

German



Service - HART mode HART offers standard and multidrop mode.

The mode "standard" with the fixed address 0 means outputting the measured value as a 4 … 20 mA signal.

In Multidrop mode, up to 15 sensors can be operated on one two-wire cable. An address between 1 and 15 must be assigned to each sensor.

6)

In this menu item you determine the HART mode and enter the address for multidrop.

HART mode

Standard

Address 0

Copy sensor data

The default setting is standard with address 0.

With this function

• Load parameter adjustment data from the sensor into the display

• and adjustment module

Write parameter adjustment data from the display and adjustment module into the sensor

The data are permanently saved in an EEPROM memory in the display and adjustment module and remain there even in case of power failure. From there, they can be written into one or several sensors or kept as backup for a possible sensor exchange.

The type and the volume of the copied data depend on the respective sensor.

Information:

Before data are written into the sensor, a check is carried out to determine whether the data fit the sensor. If the data do not fit, a fault signal is triggered or the function is blocked. When writing data into the sensor, you will see which instrument type the data originate from and which TAG-no. this sensor had.

The following items are checked:

• Software version

WHG approval

SIL activated

• Measuring principle

Signal output

Copy sensor data

Copy sensor data?

Service - PIN

36

In this menu item, the PIN is activated/deactivated permanently.

Entering a 4-digit PIN protects the sensor data against unauthorized

6) The 4 … 20 mA signal of the sensor is switched off. The sensor uses a constant current of 4 mA. The measuring signal is transmitted exclusively as a digital HART signal.


Info

6 Set up with the display and adjustment module PLICSCOM access and unintentional modifications. If the PIN is activated permanently, it can be deactivated temporarily (i.e. for approx. 60 min.) in any menu item. The instrument is delivered with the PIN set to 0000.

PIN

Disable permanently?

Only the following functions are permitted with activated PIN:

•

Select menu items and show data

Read data from sensor into the display and adjustment module.

In this menu item the most important sensor information can be displayed:

• Instrument type

Serial number: 8-digit number, e.g. 12345678

Instrument type

Serial number

• Date of manufacture: Date of the factory calibration

Software version: Edition of the sensor software

Date of manufacture

Software version

• Date of last change using PC: Date of the last change of sensor parameters via PC

Last change using PC

• Sensor details, e.g. approval, process fitting, seal, measuring cell, measuring range, electronics, housing, cable entry, plug, cable length etc.

Sensor characteristics

Display now?



6.5 Menu schematic

Basic adjustment

▶ Basic adjustment

Display

Diagnostics

Service

Info

1

Min. adjustment

0.00 %

=

0.0 pF

82.5 pF

1.1

Max. adjustment

100.00 %

=

1000.0 pF

327.4 pF

1.2

Damping

0 s

Sensor-TAG

Sensor

1.5

1.3

Linearisation curve

Linear

1.4

Display

Basic adjustment

▶ Display

Diagnostics

Service

Info

Displayed value scaled 2.1

2

Unit

Volume hl

2.2

Scaling

0 % = 000.5 hl

100 % = 005.0 hl

2.3

Backlight

Switched on

▼

2.4

Diagnostics

Basic adjustment

Display

▶ Diagnostics

Service

Info

Peak value indicator

Capacit. min.: 65.7 pF

Capacit. max.: 782.4 pF

3.1

3

Sensor status

OK

3.2

Trend recording 3.3

Presentation of the trend curve



Service

Basic adjustment

Display

Diagnostics

▶ Service

Info

Current output

Characteristic: 4-20 mA

4.1

▼

Fail.mode: < 3.6 mA

▼ min. current: 4 mA

▼

4

HART mode

Standard

Address 0

4.5

Simulation

Start simulation?

4.2

Reset

Select reset?

4.3

Language

Deutsch

▼

4.4

Copy sensor data

Copy sensor data?

4.6

PIN

Enable?

4.7

Info

Basic adjustment

Display

Diagnostics

Service

▶ Info

Instrument type

Serial number

12345678

5

5.1

Date of manufacture

06. February 2012

Software version

1.30

5.2

Last change using PC

05. March 2012

5.3

Sensor characteristics

Display now?

5.4

6.10 Saving the parameterisation data

We recommended writing down the adjustment data, e.g. in this operating instructions manual, and archiving them afterwards. They are thus available for multiple use or service purposes.

If VEGACAL 63 is equipped with a display and adjustment module, the most important data can be read out of the sensor into the display and adjustment module. The procedure is described in the operating instructions manual "Display and adjustment module" in the menu item "Copy sensor data". The data remain there permanently even if the sensor power supply fails.

If it is necessary to exchange the sensor, the display and adjustment module is inserted into the replacement instrument and the data are written into the sensor under the menu item "Copy sensor data".


7 Set up with PACTware and other adjustment programs

7 Set up with PACTware and other adjustment programs

7.1 Connect the PC

VEGACONNECT directly on the sensor

2

1

3

VEGACONNECT externally

Fig. 22: Connection of the PC via VEGACONNECT directly to the sensor

1 USB cable to the PC

2 VEGACONNECT

3 Sensor

1 2

40

OPEN

TWIST

LOCK

USB

3

4

Fig. 23: Connection via VEGACONNECT externally

1 I²C bus (com.) interface on the sensor

2 I²C connection cable of VEGACONNECT

3 VEGACONNECT

4 USB cable to the PC

Necessary components:

•

VEGACAL 63

PC with PACTware and suitable VEGA DTM


VEGACONNECT via HART


• VEGACONNECT

Power supply unit or processing system

4

1 2

Prerequisites

3

Fig. 24: Connecting the PC via HART to the signal cable

1 VEGACAL 63

2 HART resistance 250 Ω (optional depending on evaluation)

3 Connection cable with 2 mm pins and terminals

4 Processing system/PLC/Voltage supply

Necessary components:

• VEGACAL 63

PC with PACTware and suitable VEGA DTM

VEGACONNECT

• HART resistance approx. 250 Ω

Power supply unit or processing system

Note:

With power supply units with integrated HART resistance (internal resistance approx. 250 Ω), an additional external resistance is not necessary. This applies, e. g. to the VEGA instruments VEGATRENN

149A, VEGADIS 371, VEGAMET 381. Common Ex separators are also usually equipped with a sufficient current limitation resistance.

In such cases, VEGACONNECT 4 can be connected parallel to the

4 … 20 mA cable.

7.2 Parameter adjustment with PACTware

For parameter adjustment of the instrument via a Windows PC, the configuration software PACTware and a suitable instrument driver

(DTM) according to FDT standard are required. The latest PACTware version as well as all available DTMs are compiled in a DTM Collection. The DTMs can also be integrated into other frame applications according to FDT standard.

Note:

To ensure that all instrument functions are supported, you should always use the latest DTM Collection. Furthermore, not all described functions are included in older firmware versions. You can download the latest instrument software from our homepage. A description of the update procedure is also available in the Internet.



Further setup steps are described in the operating instructions manual "DTM Collection/PACTware" attached to each DTM Collection and which can also be downloaded from the Internet. Detailed descriptions are available in the online help of PACTware and the DTMs.

Standard/Full version

Fig. 25: Example of a DTM view

All device DTMs are available as a free-of-charge standard version and as a full version that must be purchased. In the standard version, all functions for complete setup are already included. An assistant for simple project configuration simplifies the adjustment considerably.

Saving/printing the project as well as import/export functions are also part of the standard version.

In the full version there is also an extended print function for complete project documentation as well as a save function for measured value and echo curves. In addition, there is a tank calculation program as well as a multiviewer for display and analysis of the saved measured value and echo curves.

The standard version is available as a download under www.vega.com/downloads. The full version is available on CD from the agency serving you.

7.3 Parameter adjustment with AMS™ and PDM

For VEGA sensors, instrument descriptions for the adjustment programs AMS™ and PDM are available as DD or EDD. The instrument descriptions are already implemented in the current versions of

AMS™ and PDM.

For older versions of AMS™ and PDM, a free-of-charge download is available via Internet. Move to www.vega.com.



7.4 Saving the parameterisation data

It is recommended to document or save the parameter adjustment data. That way they are available for multiple use or service purposes.

The VEGA DTM Collection and PACTware in the licensed, professional version provide suitable tools for systematic project documentation and storage.


8 Maintenance and fault rectification

8 Maintenance and fault rectification

8.1 Maintenance

If the device is used properly, no special maintenance is required in normal operation.

Reaction when malfunction occurs

Causes of malfunction

8.2 Rectify faults

The operator of the system is responsible for taking suitable measures to rectify faults.

VEGACAL 63 offers maximum reliability. Nevertheless, faults can occur during operation. These may be caused by the following, e.g.:

• Sensor

Process

• Voltage supply

Signal processing

Fault rectification

24 hour service hotline

The first measures to be taken are to check the output signals as well as to evaluate the error messages via the display and adjustment module. The procedure is described below. Further comprehensive diagnostics can be carried out on a PC with the software PACTware and the suitable DTM. In many cases, the causes can be determined and the faults rectified this way.

Should these measures not be successful, please call in urgent cases the VEGA service hotline under the phone no. +49 1805 858550.

The hotline is manned 7 days a week round-the-clock. Since we offer this service worldwide, the support is only available in the English language. The service is free, only standard call charges are incurred.

Check the 4 … 20 mA signal

Connect a multimeter in the suitable measuring range according to the wiring plan.

Error

4 … 20 mA signal not stable

Reason

Level fluctuations

4 … 20 mA signal missing Wrong connection

Current signal greater than

22 mA or less than 3.6 mA

Rectification

Set damping via the display and adjustment module

No power supply

Operating voltage too low or load resistance too high

Shortcircuit in the probe, e.g. because of moisture in the housing

Electronics module defective

Check connection according to chapter "Connection

steps" and if necessary, correct according to chapter

"Wiring plan"

Check cables for breaks; repair if necessary

Check, adapt if necessary

Remove the electronics module. Check the resistance between the marked plug connections. See the following instructions.

Exchange the instrument or send it in for repair


Check the resistance in the probe


Remove the electronics module. Check the resistance between the two plug connections.

There must no longer be a connection (high impedance). If there is still a connection, exchange the instrument or return it for repair

1 2 3

Fig. 26: Check the resistance in the probe

1 Shielding

2 Measuring probe

3 Ground potential

In Ex applications, the regulations for the wiring of intrinsically safe circuits must be observed.

Error messages via the display and adjustment module

Error

E013

E017

E036

Reason no measured value available

Shortcircuit in the probe, e.g. because of moisture in the housing

Rectification

•

Probe insulation damaged, short-circuit due to per-

• meating, conductive medium

Exchange the instrument or send it in for repair

• Remove the electronics module out of the probe and check the resistor between the two marked plug connections according to the figure in paragraph "Check

the resistance in the probe".

•

There should be no contact between any of the connections (high resistance)

•

If there is still a connection, exchange the instrument or return it for repair

Adjustment span too small Carry out a fresh adjustment and increase the distance between min. and max. adjustment no operable sensor software

Carry out a software update or send instrument for repair

Reaction after fault rectification

Depending on the reason for the fault and the measures taken, the steps described in chapter "Set up" may have to be carried out again.

8.3 Exchanging the electronics module

If the electronics module is defective, it can be replaced by the user.



Sensor serial number

In Ex applications, only instruments and electronics modules with appropriate Ex approval may be used.

If there is no electronics module available on site, one can be ordered from the VEGA agency serving you.

The new electronics module must be loaded with the order data of the sensor. These are the options:

• At the factory by VEGA

Or on site by the user

In both cases, the sensor serial number is needed. The serial numbers are stated on the type label of the instrument or on the delivery note.

Information:

When loading on site, the order data must first be downloaded from the Internet (see operating instructions manual "Electronics module").

Assignment The electronics modules are adapted to the respective sensor and differ in their signal output or in their power supply. You can find a suitable electronics module in the following overview.

The oscillators differ only in their signal output and are suitable for all series 60 sensors.

The following types are available:

• CL-E60H (4 … 20 mA/HART)

CL-E60P (Profibus PA)

CL-E60F (Foundation Fieldbus)

In Ex applications only an electronics module with respective Ex approval may be used.

8.4 How to proceed if a repair is necessary

You can find an instrument return form as well as detailed information about the procedure in the download area of our homepage: www.vega.com.

By doing this you help us carry out the repair quickly and without having to call back for needed information.

If a repair is necessary, please proceed as follows:

• Print and fill out one form per instrument

Clean the instrument and pack it damage-proof

Attach the completed form and, if need be, also a safety data sheet outside on the packaging

• Please contact the agency serving you to get the address for the return shipment. You can find the agency on our home page www.vega.com.


9 Dismount

9 Dismount

9.1 Dismounting steps

Warning:

Before dismounting, be aware of dangerous process conditions such as e.g. pressure in the vessel or pipeline, high temperatures, corrosive or toxic products etc.

Take note of chapters "Mounting" and "Connecting to power supply" and carry out the listed steps in reverse order.

9.2 Disposal

The instrument consists of materials which can be recycled by specialised recycling companies. We use recyclable materials and have designed the electronics to be easily separable.

WEEE directive 2002/96/EG

This instrument is not subject to the WEEE directive 2002/96/EG and the respective national laws. Pass the instrument directly on to a specialised recycling company and do not use the municipal collecting points. These may be used only for privately used products according to the WEEE directive.

Correct disposal avoids negative effects on humans and the environment and ensures recycling of useful raw materials.

Materials: see chapter "Technical data"

If you have no way to dispose of the old instrument properly, please contact us concerning return and disposal.


10 Supplement

10 Supplement

10.1 Technical data

General data

Material 316L corresponds to 1.4404 or 1.4435

Materials, wetted parts

Ʋ Process fitting - thread

Ʋ Process fitting - flange

Ʋ Process seal

Ʋ insulation (fully insulated)

316L, St C22.8 (1.0460), Alloy C22 (2.4602)

316L, Alloy C22 (2.4602), PTFE-plattiert

Klingersil C-4400

PTFE, PE

316L Ʋ Probe (rod fully insulated:

ø 12 mm/0.472 in)

Ʋ Probe (rod fully insulated:

ø 16 mm/0.63 in)

Materials, non-wetted parts

316L

Ʋ Plastic housing

Ʋ Aluminium die-cast housing plastic PBT (Polyester)

Aluminium die-casting AlSi10Mg, powder-coated - basis:

Polyester

316L Ʋ Stainless steel housing (precision casting)

Ʋ Stainless steel housing (electropolished)

316L

Ʋ Seal between housing and housing lid Silicone

Ʋ Ground terminal 316L

Ʋ Cable gland

Ʋ Sealing, cable gland

Ʋ Blind plug, cable gland

Process fittings

PA, stainless steel, brass

NBR

PA

Ʋ Pipe thread, cylindrical (DIN 3852-A) G½, G¾, G1, G1½

Ʋ Pipe thread, conical (ASME B1.20.1) ½ NPT, ¾ NPT, 1 NPT, 1½ NPT

Ʋ Flanges

Weight

DIN from DN 20, ASME from 1"

0.8 … 4 kg (0.18 … 8.82 lbs) Ʋ Instrument weight (depending on process fitting)

Ʋ Rod weight: ø 10 mm (0.394 in)

Ʋ Rod weight: ø 16 mm (0.63 in)

400 g/m (4 oz/ft)

1100 g/m (12 oz/ft)

Sensor length (L)

Ʋ Process fitting: thread and flanges 0.1 … 6 m (0.328 … 19.69 ft)

Ʋ Process fitting: Flanges - PTFE plated 0.15 … 6 m (0.492 … 19.69 ft)

Max. lateral lod - rod: ø 10 mm (0.394 in) 10 Nm (7.4 lbf ft)

Max. lateral load - rod: ø 16 mm (0.63 in) 10 Nm (7.4 lbf ft)

Torque of the flange screws (min.) 60 Nm (44.25 lbf ft)


10 Supplement

Max. torque (process fitting - thread) - rod: ø 10 mm (0.394 in)

Max. torque (process fitting - thread) - rod: ø 16 mm (0.63 in)

100 Nm (73 lbf ft)

100 Nm (73 lbf ft)

Torque for NPT cable glands and Conduit tubes

Ʋ Plastic housing

Ʋ Aluminium/Stainless steel housing max. 10 Nm (7.376 lbf ft) max. 50 Nm (36.88 lbf ft)

Output variable

Output signal

HART output values

Ʋ HART value (Primary Value)

Ʋ HART value (Secondary Value)

4 … 20 mA/HART

Capacitance

Capacitance - scaled

Resolution 1.6 µA

Fault signal, current output (adjustable) mA value unchanged 20.5 mA, 22 mA, < 3.6 mA (adjustable)

Current limitation

Load

22 mA see load diagram under Power supply

Damping (63 % of the input variable)

Rise time

Met NAMUR recommendation

0 … 999 s, adjustable

500 ms (ti: 0 s, 0 … 100 %)

NE 43

Input variable

Measured variable

Measuring principle

Measuring range

Measuring frequency

Level of liquids phase-selective admittance processing (PSA)

0 … 3000 pF

270 kHz

Accuracy (according to DIN EN 60770-1)

Reference conditions according to DIN EN 61298-1

Ʋ Temperature

Ʋ Relative humidity

+18 … +30 °C (+64 … +86 °F)

45 … 75 %

860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig) Ʋ Air pressure

Temperature error

Ʋ < 120 pF

Ʋ > 120 pF

Linearity error

< 1 pF

1 % of the current measured value

< 0.25 % of the complete measuring range

Ambient conditions

Ambient, storage and transport temperature

-40 … +80 °C (-40 … +176 °F)


10 Supplement

Process conditions

Process pressure

Ʋ Threaded versions

Ʋ Flange version

-1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig), depending on the process fitting

-1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig), depending on the process fitting

Ʋ Flange version ≥ 3"/DN 80, plated -0.4 … 64 bar/-40 … 6400 kPa (-5.8 … 928 psig), depending on the process fitting

Process temperature VEGACAL 63 of 316L

Ʋ Insulation PE

Ʋ Insulation PTFE

-40 … +80 °C (-40 … +176 °F)

-50 … +150 °C (-58 … +302 °F)

Process temperature (thread or flange temperature) with temperature adapter

(option with PTFE)

-50 … +200 °C (-58 … +392 °F)

Process temperature VEGACAL 63 of St C22.8

Ʋ Insulation PE

Ʋ Insulation PTFE

-20 … +80 °C (-4 … +176 °F)

-20 … +150 °C (-4 … +302 °F)

2

80°C

(176°F)

3

40°C

(104°F)

0°C

(32°F)

-50°C

(-58°F)

-40°C

(-40°F)

50°C

(122°F)

Fig. 27: Ambient temperature - Process temperature

1 Process temperature

2 Ambient temperature

3 Temperature range with temperature adapter

Dielectric constant ≥ 1.5

100°C

(212°F)

150°C

(302°F)

1

200°C

(392°F)

Electromechanical data - version IP 54

Cable entry

Ʋ Sensor housing (BNC plug)

Ʋ External housing

– 1 x BNC plug

– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm)


Cable entry

Ʋ Sensor housing (hexagon housing)

Ʋ External housing

Screw terminals


– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm) for wire cross-section up to 2.5 mm² (AWG 14)


10 Supplement


Cable entry

Ʋ Sensor housing (lateral cable outlet)

Ʋ External housing

Screw terminals


– 1 x cable entry M16 x 1.5 (cable ø 3.5 … X mm) for wire cross-section up to 2.5 mm² (AWG 14)

Electromechanical data - version IP 66/IP 67 and IP 66/IP 68; 0.2 bar

Cable entry/plug 7)

Ʋ Single chamber housing – 1 x cable gland M20 x 1.5 (cable: ø 5 … 9 mm), 1 x or: blind plug M20 x 1.5

– 1 x closing cap M20 x 1.5; 1 x blind plug M20 x 1.5

or:

Ʋ Double chamber housing

Spring-loaded terminals for wire crosssection

– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT or:

– 1␣x plug (depending on the version), 1␣x blind stopper

M20␣x␣1.5

– 1 x cable entry M20 x 1.5 (cable: ø 5 … 9 mm), 1 x blind plug M20 x 1.5; 1 x blind plug M16 x 1.5 or or: optionally available with 1 x plug M12 x 1 for external display and adjustment unit

– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT, 1 x blind plug M16 x 1.5 or optionally 1 x plug M12 x 1 for exteror: nal display and adjustment unit

– 1 x plug (depending on the version), 1 x blind plug

M20 x 1.5; 1 x blind plug M16 x 1.5 or optionally available with 1 x plug M12 x 1 for external display and adjustment unit

< 2.5 mm² (AWG 14)

Electromechanical data - version IP 66/IP 68 (1 bar)

Cable entry

Ʋ Single chamber housing

Ʋ Double chamber housing

1 x IP 68 cable gland M20 x 1.5; 1 x blind plug M20 x 1.5

1␣x IP␣68 cable gland M20␣x␣1.5; 1␣x blind stopper

M20␣x␣1.5; 1␣x blind stopper M16␣x␣1.5

Connection cable

Ʋ Wire cross-section

Ʋ Wire resistance

Ʋ Tensile strength

Ʋ Standard length

Ʋ Max. length

0.5 mm² (AWG 20)

< 0.036 Ω/m (0.011 Ω/ft)

< 1200 N (270 lbf)

5 m (16.4 ft)

1000 m (3280 ft)

7) Depending on the version M12 x 1, according to DIN 43650, Harting, 7/8" FF.


10 Supplement

Ʋ Min. bending radius

Ʋ Diameter approx.

Ʋ Colour - standard PE

Ʋ Colour - standard PUR

Ʋ Colour - Ex-version

25 mm (0.984 in) with 25 °C (77 °F)

8 mm (0.315 in)

Black

Blue

Blue

Display and adjustment module

Voltage supply and data transmission

Indication

Adjustment elements through the sensor

LC display in dot matrix

4 keys

Protection rating

Ʋ unassembled IP 20

Ʋ mounted into the sensor without cover IP 40

Ambient temperature - Display and adjustment module

-20 … +70 °C (-4 … +158 °F)

Material

Ʋ Housing

Ʋ Inspection window

ABS

Polyester foil

Voltage supply

Operating voltage U

B

Ʋ Non-Ex instrument

Ʋ Ex ia instrument

Ʋ Ex-d-ia instrument

12 … 36 V DC

12 … 30 V DC

18 … 36 V DC

Operating voltage U

B

Ʋ Non-Ex instrument

- illuminated display and adjustment module

20 … 36 V DC

Ʋ Ex ia instrument

Ʋ Ex-d-ia instrument

Reverse voltage protection

20 … 36 V DC

Lighting not possible

Integrated


10 Supplement

Ω

1000

750

500

2

1

250

4

12 14 16 18 20

Fig. 28: Voltage diagram

1 HART load

2 Voltage limit Ex-ia instrument

3 Voltage limit non-Ex-/Ex-d-ia instrument

4 Operating voltage

Permissible residual ripple

Ʋ < 100 Hz

Ʋ 100 Hz … 10 kHz

Load

22 24 26 28 30 32 34 36 V

U ss

U ss

< 1 V

< 10 mV see diagram

Potential connections and electrical separating measures in the instrument

Electronics Not non-floating

Ground terminal Galvanically connected with the metal process fitting

Galvanic separation between electronics and metal housing parts

Ʋ Reference voltage 500 V AC

Electrical protective measures

Protection rating

Housing material

Plastic

Aluminium

Version

Single chamber

Double chamber

Single chamber

Double chamber

IP-protection class

IP 66/IP 67

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 68 (0.2 bar)

NEMA protection

Type 4X

Type 4X

Type 6P

Type 6P

Type 4X

Type 6P

Type 6P

Type 6P Stainless steel (electropolished)

Stainless steel (precision casting)

Single chamber

Single chamber

Double chamber

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

IP 66/IP 67

IP 66/IP 68 (0.2 bar)

IP 68 (1 bar)

Type 6P

Type 6P

Type 4X

Type 6P

Type 6P

3


10 Supplement

Connection of the feeding power supply unit

Networks of overvoltage category III

Altitude above sea level

Ʋ by default bis 2000 m (6562 ft)

Ʋ with connected overvoltage protection up to 5000 m (16404 ft)

Pollution degree 8)

Protection class

4

II (IEC 61010-1)

Functional safety (SIL)

Functional safety is already activated on instruments with SIL qualification ex factory. On instruments without SIL qualification ex factory, the functional safety must be activated by the user via the display and adjustment module or via PACTware for applications according to SIL.

Functional safety according to IEC 61508-4

Ʋ Single channel architecture (1oo1D) up to SIL2

Ʋ double channel diversitary redundant architecture (1oo2D) up to SIL3

You can find detailed information in the supplied Safety Manual of the instrument series or under

"www.vega.com", "Downloads", "Approvals".

Approvals

Instruments with approvals can have different technical specifications depending on the version.

For that reason the associated approval documents of these instruments have to be carefully noted. They are part of the delivery or can be downloaded under www.vega.com "Instrument

search (serial number)" as well as in the general download area.

8) When used with fulfilled housing protection


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10.2 Dimensions

Housing in protection IP 66/IP 68 (0.2 bar)

~ 69 mm

(2.72")

ø 77 mm

(3.03")

~ 116 mm (4.57")

ø 84 mm (3.31")

~ 87 mm (3.43")

ø 84 mm

(3.31")

M16x1,5

M20x1,5/

½ NPT

1

~ 59 mm

(2.32")

ø 80 mm

(3.15")

M20x1,5/

½ NPT

M20x1,5

2

~ 69 mm

(2.72")

ø 77 mm

(3.03")

M20x1,5/

½ NPT

3

~ 87 mm (3.43")

ø 84 mm

(3.31")

M16x1,5

M20x1,5/

½ NPT

M20x1,5/

½ NPT

4 5 M20x1,5/

½ NPT

6

Fig. 29: Housing versions with protection rating IP 66/IP 68 (0.2 bar) - with integrated display and adjustment module the housing is 9 mm/0.35 in higher

1 Plastic single chamber (IP 66/IP 67)

2 Aluminium - single chamber

3 Aluminium - double chamber

4 Stainless steel single chamber (electropolished)

5 Stainless steel single chamber (precision casting)

6 Stainless steel double chamber housing (precision casting)


10 Supplement

Housing in protection IP 66/IP 68 (1 bar)

~ 150 mm (5.91")

ø 84 mm (3.31")

~ 103 mm

(4.06")

ø 77 mm

(3.03")

~ 105 mm (4.13")

ø 84 mm

(3.31")

M16x1,5

M20x1,5 M20x1,5 M20x1,5

1 2 M20x1,5/

½ NPT

3

Fig. 30: Housing version with protection rating IP 66/IP 68 (1 bar) - with integrated display and adjustment module the housing is 9 mm/0.35 in higher

1 Aluminium - single chamber

2 Stainless steel single chamber (precision casting)

2 Stainless steel double chamber housing (precision casting)

56 mm (2.21")

22 mm (0.86")

G¾, G 1, G 1½

Fig. 31: VEGACAL 63, threaded version G1 (ISO 228 T1)

L Sensor length, see chapter "Technical data"

ø 16mm

(0.63")


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Fig. 32: Temperature adapter

ø 40 mm (1.58")

ø 27 mm

(1.06")

Fig. 33: VEGACAL 63, concentric tube, for example with small dielectric constant or for linearization

L Concentric tube length, see chapter "Technical data"


10 Supplement

10.3 Industrial property rights

VEGA product lines are global protected by industrial property rights. Further information see www.vega.com.

VEGA Produktfamilien sind weltweit geschützt durch gewerbliche Schutzrechte.

Nähere Informationen unter www.vega.com.

Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellectuelle. Pour plus d'informations, on pourra se référer au site www.vega.com.

VEGA lineas de productos están protegidas por los derechos en el campo de la propiedad industrial. Para mayor información revise la pagina web www.vega.com.

Линии продукции фирмы ВЕГА защищаются по всему миру правами на интеллектуальную собственность. Дальнейшую информацию смотрите на сайте www.vega.com.

VEGA系列产品在全球享有知识产权保护。

进一步信息请参见网站<www.vega.com。

10.4 Trademark

All the brands as well as trade and company names used are property of their lawful proprietor/ originator.


Notes


Printing date:

All statements concerning scope of delivery, application, practical use and operating conditions of the sensors and processing systems correspond to the information available at the time of printing.

Subject to change without prior notice

© VEGA Grieshaber KG, Schiltach/Germany 2017

VEGA Grieshaber KG

Am Hohenstein 113

77761 Schiltach

Germany

Phone +49 7836 50-0

Fax +49 7836 50-201

E-mail: [email protected]

www.vega.com

Vega VEGACAL 63 Capacitive rod probe for continuous level measurement Operating instructions

Operating Instructions

Capacitive rod electrode for continuous level measurement

VEGACAL 63

Contents

1 About this document

1.1 Function

1.2 Target group

1.3 Symbols used

•

→

2 For your safety

2.1 Authorised personnel

2.2 Appropriate use

2.3 Warning about incorrect use

2.4 General safety instructions

2.5 Safety label on the instrument

2.6 EU conformity

2.7 Fulfillment of NAMUR recommendations

2.8 Installation and operation in the USA and

Canada

2.9 Safety instructions for Ex areas

2.10 Environmental instructions

3 Product description

3.1 Configuration

3.2 Principle of operation

3.3 Adjustment

3.4 Packaging, transport and storage

3.5 Accessories and replacement parts

4 Mounting

4.1 General instructions

4.2 Mounting instructions

5 Connecting to power supply

5.1 Preparing the connection

5.2 Connection procedure

5.3 Wiring plan, single chamber housing

5.4 Wiring plan, double chamber housing

5.5 Wiring plan, Ex-d double chamber housing

5.6 Wiring plan - version IP 66/IP 68, 1 bar

6 Set up with the display and adjustment module PLICSCOM

6.1 Short description

6.2 Insert display and adjustment module

6.3 Adjustment system

6.4 Setup steps

6.5 Menu schematic

6.10 Saving the parameterisation data

7 Set up with PACTware and other adjustment programs

7.1 Connect the PC

7.2 Parameter adjustment with PACTware

7.3 Parameter adjustment with AMS™ and PDM

7.4 Saving the parameterisation data

8 Maintenance and fault rectification

8.1 Maintenance

8.2 Rectify faults

8.3 Exchanging the electronics module

8.4 How to proceed if a repair is necessary

9 Dismount

9.1 Dismounting steps

9.2 Disposal

10 Supplement

10.1 Technical data

10.2 Dimensions

10.3 Industrial property rights

10.4 Trademark

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